Unitary impervious container



March 6, 1956 G. A. MOORE 2,737,335

UNITARY IMPERVIOUS CONTAINER Filed May 28, 1952 VIEI. 2

IN V EN TOR.

United States Patent 0 NITARY HVIPERVIUS CONTAINER George Arlington Moore, New York, N. Y.

Application May 28, 1952, Serial No. 290,454

13 Claims. (Cl. 229-16) This invention relates to improvements in hermetically sealed containers made from a single blank of sheet material. The sheet materials for making the containers comprise aluminum foil, plain or laminated with other sheet material, the aluminum sheet having surfaces of plastic iilm, such as polyethylene, Saran or other suitable substantially impervious lm having thermoplastic properties.

The container of this invention is substantially impervious and especially adapted for distribution of hygroscopic food-studs and such other commodities requiring protection against elements of the atmosphere.

Conventional containers quite extensively used for distribution of food-stuffs are classed as folding cartons having inner liners or bags made of various sheet materials which provide better protection for the product than the plain carton without such inner material. To further protect the product, the lined cartons are wrapped exteriorly with various kinds of printed sheet materials such as waxed papers, cellophane or aluminum foil laminated with waxed paper. These wrappers at times subject the product in the carton to contaminating odors from the carton board material. These conventional cartons require considerable handling in packing operations. The packers must maintain an inventory of various materials rarely balanced.

Another type of conventional container used for the distribution of products such as dehydrated soups and other hygroscopic products, consists of a pouch or envelope made of heat-scalable aluminum foil. This type of container is employed by some packers because the interior of the container does not have exposures of detrimental raw wicking edges of material, however, these containers are without structural rigidity, and must be provided with relatively large area of opposing wall material to provide space for the product otherwise, they could not be closed and sealed in a practical manner. The seams of the container however, buckle and distort the containers when closing and sealing the filling end thereof.

It is an object of this invention to provide a substantially impervious and hermetically sealed container made from a single blank of sheet material.

Another object of the invention is to provide a container having a bottom reinforced with corner pleats adapted to hermetically seal the bottom corners.

A further object of this invention is to provide a container having opposed gusset folds adapted to be folded and sealed in blending co-acting relation with end closures to form a closure seam having a substantially uniform thickness.

These and other objects of the invention will be apparent upon reading the following descriptive disclosure read in conjunction with the illustrative accompanying drawings, wherein:

Fig. l is a perspective View of a completed container,

Fig. 2 is a plan view of a unitary blank of which the container is constructed,

ICC

Fig. 3 is a fragmentary view in perspective of the container in a partial stage of assembly,

Fig. 4 is a fragmentary view in perspective of the assembled container,

Fig. 5 is a fragmentary side elevation of a portion of an end closure of the container, v

Fig. 6 is a fragmentary view in cross-section taken on line 6-6 of Fig. 5 and showing fragmentary parts of closure sealing tools, and

Fig. 7 is a fragmentary View in perspective of a top portion of the container.

Referring to the Fig. 2, a blank 4 having longitudinal edges 4a and 4b is composed of a central area 5, which constitutes the bottom of the container, and two longitudinal areas 8 extending laterally from each sideof the central area S, these identical areas 8 constituting the opposed side walls of the container and longitudinally extend to edges 8a, said areas 8 being bounded by longitudinal parallel lines 6 and transverse lines 7. Disposed on the top and bottom of central area 5 are identical areas 16. Disposed to the left side of these areas 16 of Fig. 2 are identical lateral areas 17, said lateral areas extend longitudinally to sloping lines 22 and 23, and are further bounded by cut lines 18 and lines 7a on that edge of the area 17 opposed to the edge having sloping edges 22 and 23. The areas 17 are longitudinally bounded by lines 6, and edges 4a and 4b as the case may be.

Disposed to the right side of lateral areas 16 are identical lateral areas 17 having W-shaped transverse edges, said W-shaped edges consisting of lines 26, 27, 2S and 28'. The lateral areas 17 are further bounded by longitudinal lines 6 and edges 4a and 4b, as the case may be. The areas 17 also have a transverse line consisting of cut line 18 and linearly extending line 7a, which transverse line oppositely is disposed to the W- shaped edge of said transverse areas 17 The areas 8 are composed of sub-areas 11,' 12 and 13. The areas 11 disposed to the right and left relative to the central area 5, are bounded on their inner sides, which sides are transverse to the blank 4, by lines 9 and 10 respectively. The outer transverse sides of areas 11 are defined by lines 14. The areas 12 are dened by line 14 and line 15 parallel thereto, and also by the end portions of line 6. The areas 13 are dened as being disposed outwardly of line 15.

Disposed in areas 17 and 17v and adjacent tothe corners of the central area 5 are identical sub-areas 21, having a wing-like shape. These wing-like sub-areas 21 are triangular and are defined by cut-lines 19, and lines 2d and 7a. Lines 20 extend outwardly from the corners of the central area 5 at an angle of about 45 degrees relative to lines 6 and 7a.

The areas 17 are provided with sloping edges 22 and 23 which slope to a common edge 24, which edges 24 are substantially parallel to the edges 4a and 4b of the blank. The said areas 17 are provided with fold lines, which lines are continuations of lines 10 and 14, forming a rst sub-area 25a and a second sub-area 23a. The area 23a is divided by a medial line 24a, which medial line is a continuation of edge 24. The areas 25a is divided by two lines 25, which slope outwardly from medial lines 24a to the corners of areas 25a formed by line 10, lines 6 and the respective edges ofthe blank.

The areas 17 having the transverse Vil-shaped edges, are provided with three sub-areas 31, 32, and 33 outwardly of fold line 9 which extends across the areas 17 to the edges 4a and 4b of the blank. The areas 31 are substantially isosceles triangles having portions of said line'9 as their base and having sloping sides delined by edges 26 and 27 and linearly extending fold lines 29 and 30. The said sloping lines 29 and 30 form angles of about 45 degrees with their base line 9. The areas 32 are defined by edges 28, 1fold lines 29, and end portion of the longitudinal edges of the bla-nk 4. The areas 33 are defined by edges 28', fold lines 30, and the end portions of lines 6. The triangular areas- 3 2 are larger than triangular areas 33 to provide for imbrication-to effect 1an imbriated folded gusset as shown in Fig. 5 by lines 28 and 28. I 4 4 The material of,y blank 4 is preferably aluminum foil of three quarter to full hardness, andof an approximate range of thickness from 0.002 to 0.006 inch. Another suitable material may be a laminated sheet consisting of a core sheet having aluminumon both sides. vBoth of the said materials are provided on one side with a thermoplastic lm of dry adhesive.

In forming a container from the blank described above, the blankis folded over a mandrel to form the container 34 (Fig. 3). The central area '5 of the blank engages the end of the mandrel to form the bottom wall of the container. The opposing areasv16 are folded inwardly to engage two opposing end walls of the mandrel. The wing-like .portions 21 fold on lines 2t) simultaneously as the'adjacent wall areas 8 are folded to engage the opposing walls of the mandrel. The wall areas 17 are folded over the inner wall areas 16, the wing-like areas 21 forming pleated folds outwardly of the wall area 16, adjacent the bottom corners of the container. The cut edges V18 Vof the innerwall areas 16 abut the wall areas 8. The edges 4a and 4b of the wall areas 17 abut one wall area 8. The pleated folds of the formed container leave the cut edges 19 exposed on the outer side of the wall areas V16. The pleated folds inwall area 17 are covered by the overlapping wallareas 17', which are folded over cand enclose th'e'walls 17. The pleated folds of the overlapping walls 17 engage areas of the outer walls 17, leavingexposed 'notches 35 (Fig. 4) in the two opposed end walls 17,'adja`cent the bottom of vthe container, with the two notches bein'g'adjacent'a single'side wall area 8.

The container (Fig. 4) "comprises a bottom integrally united to four vertical w'alls,'two` of which are opposed walls having multiple thickness. yIn the container of this invention the lower parts of the said opposingwalls 17 :and 17 have l'wall lareas closing and reinforcing the corners adjacent the bottom ofthe container. The inner kwall areas 16 provide suppofts for the pleated folds 21 of the adjacent'walls 17. The'pair of pleated folds in the wall areas 17 enclose Vand reinforce the corners of the bottom' of the'contain'er. `Walls 17 as a result cover the pleated folds of wall areas `17.

y Pressure and heat is then applied to`the multiple opposed end walls consisting of wall areas 16, 17 and 17 of the formed container. The heat of the sealing irons activates the thermoplastic iilm on the respective surfaces of the overlapping walls 16, 17 and 17', uniting them in seamformingrelationship. The' faces of the sealing irons are machined to have face contour to accommodate'the multiple thickness of inwardly folded wall material adjacent to the bottom ofthe container.

The` container 34 (Fig. l) is 'closed and sealed by ypressing the opposed triangular areas '31 (Fig. 4) in- `wardly from fold lines 9. Triangular areas 32 and 33 bend inwardly onlines Vl29V and 30. The exposed porvrtions of the Walls 17 are folded inwardly on line 24a, the

ktriangularareas31 thereby forming opposed gussets. The opposed wall areas 11 are bent inwardly and downwardly on the fold lines 9 and '10, the upper walls 12 remaining substantially upright from the lines 14 and clamp wall -areas 24a of the gussets.

The gussets have stepped edges (Fig. imbricated by the clamping walls 12. The edges 22 and 23 slope downwardly progressively -in spaced apart relationship. The triangular areas 32 and 33 have edges sloping downwardly also in progressively spaced apart relationship. This separation of edges removes excess bulk material 'from the seam area of the closure. The folds are sealed d together with sealing tools y(Fig. 6). M'ale and 'female members 36 and 37 are equipped with suitable heating means such as electrical heating elements 38 connected with a source of electrical current. The male member 36 is provided with a bead 39. The female member 37 has a circular recess 40. The tools are controlled by suitable mechanism to move inwardly in opposed relationship and to exert suitable pressure to the folded walls of the closure. The bead 39 of the male member compresses the material into the recess it? of the female member, thereby blending the edges of the gusset folds with the other walls while forming a rib like recess 4i (Fig. l) across the closure of the container. The heat from the sealing tools activates the thermoplastic adhesive on the inner walls of the folded closure thereby uniting the respective surfaces. The opposed wall areas 13 may be folded to overlap each other, thereby facilitating the further folding of the seamed part of the closure (Fig. 7).

Vhile the container of this invention may be made of anyl suitable material, it is preferable to employ substantially impervious material when the `container is employed for hygroscopic products. The material used is preferably metallic, such as aluminum in the form of aluminum sheet or'laminates thereof. Plastic lrn sheet material may be employed to fabricate the container. The sheet of plastic ilm may be laminated with other more rigid sheet material.

i claim:

l. A iiat walled containerV made from a single blank and comprising a bottom wall, two opposing side walls, and two opposing multiple end walls, said multiple end walls each including a rst longitudinal end wall member integrally united with a first side wall and a second outermost longitudinal end wali member integrally united with a second side wall, each said first end wall member having a top edge consisting of sloping edges converging to longitudinally spacedcontact with a common medial edge extending intermediately of the side edges of and along said first end wall, and each said second end wall member having a W-shaped top edge, the apex centrally disposed in each W being in line with and in spaced relation downwardly from the medial edge of the top edge of the opposing longitudinal end member, thereby forming at the top of each multiple end wall an outer wall top extremity in the shape of a W, and an inner wall top extremity extending above said W and defined by the before mentioned edges converging to spaced contact with the particular common medial edge.

2. A container structure as defined in claim l wherein the W side edges and the converging edges at `each multiple end top extremity each lie in a distinct angular position so that when said edges are folded into a gusset fold in effecting a closure of the container all edges of a given top extremity will lie in a distinct, bulk minimizing position.

3.7The container structure of claim 2 wherein each said side wall has a plurality of integrally united closure wall areas consisting of a first closure wall area, one said first closure area being'aligned with the two gussetvpart areas of the end'walls 'in which the central inverted V parts of the Ws are formed and the other first closure area being aligned with the two gusset part areas of the end walls which'are lapped bysaid' central V parts of the Ws, second closurewallareas above thefirst closure wallareas and integrally united thereto, one of said second closure wall areas beingaligned with the two gusset'part areas of theend walls in which the converging top'edges denne the end wall extremity and the other of said second closure'wall areas being aligned with the two gusset part areas of the end walls into which the W side legs extend, said second closure wall'areas being adapted to contact each other in opposing clamped area-rela- -tionship in co-action with the said gusset fold, tolform an imbricated folded gusset. and third top closure wall areas integrally united with the said second 'closure areas and adapted to be freely` folded-over said opposing clamped second area, said folded-over third closure area being in non-adhesive relationship, thereby forming finger grasps to facilitate the opening of the container.

4. The container structure of claim 3 wherein said clamped second closure wall areas are united by pressure heat sealing means to form a recessed rib across the closure, and thereby blend the imbn'cated edges of the folded gussets into a substantially uniformly thick seam.

5. In a container of the character described, a bottom, opposing side walls, and opposing end walls, each end wall comprising an inner and an outer wall, said inner and outer walls being of substantially the same width and bonded together, first fold lines extending about the side and end walls and defining the height of the container packaging enclosure, second fold lines extending about the side and end walls in parallel relation above the first fold lines and defining n each side wall a fold in closure area of at least half the width of an end wall, and in part defining in each end wall a gusset fold area adapted to be folded inwardly, each said inner end wall within its gusset fold area having fold lines which diverge downwardly from a central point at the second fold line to a base at the first fold line forming a triangular gusset portion adapted to be folded inwardly and generally horizontally, third fold lines paralleling the second fold lines downwardly from the upper edge extremities of the side walls and dividing the side wall portions above the second fold lines into upright fold areas adapted to be brought into face to face opposition with gusset fold portions between them, and into fold over iiap areas also adapted to be brought into face to face opposition, the upper edge extremity of each outer end wall being W-shaped with its inverted V center aligned with the apex of the particular inner wall triangular gusset portion and its outer legs diverging upwardly to the end wall sides at the third fold lines, and each inner end wall extending beyond the respective outer end wall and terminating in edges which converge inwardly and downwardly from said third fold lines.

6. Container structure as defined in claim 5 in which each of the diverging W outer legs of each outer end wall and each inwardly converging edge of each inner wall is disposed in a distinct angular position so that when the gusset portions defined in part by said edges are folded in between the opposing iiap areas said edges will lie in distinct positions and provide a minimum of overlapping bulk in the container closure.

7. A container having a closure comprising opposed lapping end walls each having a top portion consisting of an inner wall having inwardly sloping edges, said edges sloping inwardly to a median line at independent inclinations, an outer wall with a W-shaped edge forming an exposed area on the inner wall defined in part by the W-shaped edge and the inwardly sloping edges, a pair of opposed side walls having a plurality of successive closure wall areas at the upper edge thereof united to a respective top portion of an end wall, the central inverted V portion of each W being folded inwardly in generally 'horizontal position to form a gusset base and the remain- 'ing lapping end wall portions endwise of said central inverted V portions being folded inwardly and downwardly with the terminal ends thereof folded upwardly and in yoverlapping relation, said plurality of areas being folded inwardly in co-action with the gusset to form and imlbricate the gussets and to seam the closure walls in im- ,pervious relationship.

8. A container having a closure which comprises opposed overlapping end walls each having a top marginal :portion consisting of an inner disposed wall margin having Va central vertical edge portion joined with two opposed traverse downwardly sloping edges, one of said edges being sloped downwardly to join the lower end of said vertical edge and the other downwardly sloping edge integrally and contiguously joined with said end walls, thesaid end wall top marginal portions being folded inwardly to form opposed imbricated gussets which draw the said upwardly opposed portions of the side walls inwardly upon vertical portions of said gusset folds in seam forming relationship, said sloping edges of the inner wall portion and W-shaped edges of the outer wall portion forming imbricated layers of wall material to remove bulk of said material from within the sealed seam of the container closure.

9. A rectangular container made from a single blank of sheet material which blank being provided with surface protective materials having thermoplastic properties, said container comprising a fiat and uniformly smooth bottom end wall of single thickness being integral of two opposing side walls, and two other opposing end walls each being integral of each of said first mentioned side walls so that said end walls are of multiple thickness being bonded together in surface to surface relationship, the inner end wall layer having a longitudinal corner edge being disposed in edge to surface abutment along interior surface margin adjacent the folded longitudinal corner edge of the outer end Wall layer, each said inner end wall member being provided with a bottom edge portion that provides means to secure upwardly folded portions of said bottom end Wall, and having a top end edge consisting of sloping edges converging to longitudinally spaced contact with a common medial edge extending intermediately of the side edges of and along said inner end wall, 4and each said outer end wall member having a bottom end edge portion that provides means to further secure said upwardly folded portions of said bottom end wall, and having a substantially W-shaped top end edge, the apex'substantially central in each W being in line with and in spaced relation downwardly from the medial edge of the top edge of the opposing longitudinal inner end Wall member. thereby forming at the top of each multiple end wall an outer top extremely in substantially the shape of a W, and an inner wall top extremity extending above said W and defined by the before mentioned edges converging to spaced contact with the particular common medial edge, said W side edges and the converging edges at each multiple end top extremity each lie in a distinct angular position so that when said edges are folded into a gusset fold in effecting a closure of the container, all edges of a given top extremity will lie in a distinct bulk minimizing position so that said thermoplastic surface protective material upon the surface of said folds when being activated by heat and pressure will secure said closure in seam forming relationship.

l0. A rectangular container made from a single blank of paper board sheet material, said blank being provided with a surface protective material having thermoplastic adhesive properties, said container comprising a flat and uniform bottom wall of single thickness, two opposing side walls, and two opposing multiple end walls, said multiple end walls each including a first longitudinal end wall member being integrally united with a first side wall and a second outermost longitudinal end wall member being integrally united with a second side wall, each said first end wall member having a bottom edge portion that pro vides means to secure upwardly folded portions of said bottom wall and having a top edge consisting of sloping edges converging to longitudinally spaced contact with a common medial edge extending intermediately of the side edges of and along said first end wall, and each said second end wall member having a bottom edge portion that provides means to further secure said upwardly folded portions of said bottom wall and having a substantially W-shaped top edge, the apex substantially central in each W being in line with and in spaced relation downwardly from the medial edge of the top edge of the opposing longitudinal end member, thereby forming at the top of each multiple end wall an outer top extremity in substantially the shape of a W, and an inner wall top extremity extending above said W and defined by the before mentioned edges converging to spaced contact with the particular common medial edge, said W side edges and the converging edges at each multiple end top extremity each lie in a distinct angular position so that when said edges are folded into a gusset fold in effecting a closure of the container, all edges of a given top extremity will lie in a distinct bulk minimizing position so that said protective material having adhesive properties upon the surfaces of said folds when being activated by heat and pressure, will secure said closure in seam forming relationship.

11. A container having closure forming means comextremity of its wall portion to the top of said vertical edge, each outer wall portion overlapping said inner wall being provided with a substantially W-shaped top edge to provide means with which to expose an upper exterior surface portion of said inner wall portion downwardly of the sloping edges thereof, the outwardly opposed top i edge portions of said W-shaped edges being disposed in meeting junction with each of the outwardly opposed top edge extremity portions of said sloping edges, two other opposed adjacent side walls of the container being integrally related to said first mentioned two opposed side walls, an upper marginal portion of each first mentioned inner and outer wall being folded inwardly and down- Wardly between said two opposed adjacent walls to form a pair of opposed gusset folds so that an upper marginal portion of each gusset having the opposed sloping edges is disposed in substantially vertical position upwardly of and substantially at right angles to the folded central triangular shaped base portion of the W-shaped outer wall portion, said two adjacent side walls of the container each having a marginal portion thereof being folded over top -outer wall portions being disposed in relationship to form imbricated layers of wall material and thereby remove bulk of said wall material from the closure seam margin of the container when being sealed across the top thereof in seam forming relationship.

12. A container as set forth in claim 10 whereby said two other opposed adjacent side walls each being provided `vith an uppermost horizontal marginal wall portion, which margin extends upwardly of the uppermost top corner edges of said sloping and W-shaped edged wall portions, said horizontal margins being disposed in non-adhesive relationship to provide means for linger grasps to open the sealed seam across the top of the container and further provide thereafter folding facilities with which to reclose said container.

13. ln a container formed of a single blank of foldable sheet material, said container being provided with a body portion having four side walls and at least one of said side walls being of multiple thickness disposed in overlapping relationship to constitute a longitudinal seam for said body portion of the container comprising said one side wall of the container consisting of an inner and outer wall layer of substantially the same width and being adhered together in surface to surface bonded relationship, each of said inner and outer wall portions being alternately integral of each wall of a pair of opposed adjacent side walls of the container, an upper marginal portion of said inner wall being provided with a top edge consisting of sloping edges converging to longitudinally spaced Contact with a common medial edge extending intermediately of the side edges of and along said inner and outer wall portions, said outer wall portion of the one side Wall having a substantially W-shaped top edge, the apex centrally dispo-sed in the W being substantially in line with and in spaced relation downwardly from the medial edge of the top edge of the opposing inner wall marginal portion, thereby forming at the top of the multiple side wall portion an outer Wall top extremity in the shape of a W, and an inner wall top extremity extending above said W and defined by the before mentioned edges con verging to spaced contact with the common medial edge.

References Cited in the file of this patent UNITED STATES PATENTS 1,591,427 Leary July 6, 1926 1,921,150 Bomberger Aug. 8, 1933 1,973,391 Reynolds et al. Sept. 11, 1934 2,246,596 Moore June 24, 1941 2,373,701 Meredith Apr. 17, 1945 2,390,909 Zinn Dec. 11, 1945 2,417,104 Cope Mar. 11, 1947 2,437,114 Moore Mar. 2, 1948 2,524,441 Guyer Oct. 3, 1950 2,553,803 Zinn May 22, 1951 2,553,804 Zinn May 22, 1951 2,573,524 Weisberg et al. Oct. 30, 1951 2,582,286 Schenck Ian. 15, 1952 2,634,857 Weckesser Apr. 14, 1-953 2,661,141 Zinn Dec. 1, 1953 FOREIGN PATENTS 595,610 Germany Apr. .29, 1935 537,617 Great Britain June 30, 1941 586,070 Great BritainV Mar. 6, 1.947 

